Brim-forming machine and method of use

A brim-forming machine comprising

• a set of four brim formers each configured to rotate about a former axis that is spaced from every other former axis,
• a hot-air manifold coupled to the set of brim formers and configured to provide hot air to the set of brim formers, the hot-air manifold is coupled to a hot-air source including a blower configured to displace air toward the brim formers and a hot-air heater configured to heat the air displaced by the blower;
• a cold-water supply coupled to the set of brim formers in longitudinal spaced-apart relation to the hot-air manifold and configured to supply cooling water to the set of brim formers, and
• an alignment system coupled to the set of brim formers and configured to change radial positioning of each brim former in the set of brim formers,
• wherein each brim former includes a rotating spindle configured to rotate about a respective former axis and a servo motor coupled to the rotating spindle to drive rotation of the rotating spindle,
• wherein the rotating spindle includes a hot-screw section which is heated to a hot temperature by the hot air, a cold-screw section which is cooled to a cold temperature by the cooling water, and an insulation block located between the hot-screw section and the cold-screw section and configured to minimize the flow of heat from the hot-screw section to the cold-screw section and the hot temperature is greater than the cold temperature, and
• wherein the hot-screw section includes an inner cylinder that defines a first hot air passageway and an outer cylinder spaced radially from the inner cylinder such that a second hot air passageway is located between the inner cylinder and the outer cylinder.